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New manufacturing systems are creating a competitive world. The challenge for new facilities consists in creating lean thinking and focusing on time and waste reduction through the use of continuous improvement principles. In new facilities it is easier to create this environment.

The patho-anatomic alterations due to vertical loading of the human cervical column were documented and correlated with biomechanical kinematic data. Seven fresh human cadaveric head-neck complexes were prepared, and six-axis load cells were placed at the proximal and distal ends of the specimens to document the gross biomechanical response. Retroreflective markers were placed on bony landmarks of vertebral bodies, articular facets, and spinous processes along the entire cervical column. Targets were also placed on the occiput and arch of C1. The localized movements of these markers were recorded using a video analyzer during the entire loading cycle. Pre-test two-dimensional, and three-dimensional computerized tomography (CT), and plane radiographs were taken. The specimens were loaded to failure using an electrohydraulic testing device at a rate of 2 mm/s.

Studies were conducted on twenty-two fresh human cadavers to determine the probability of facial bone fracture following dynamic contact with steering wheel assemblies of both standard (a commercially available) and energy absorbing (EA) types. Using a specially designed and validated vertical-drop impact test system, either zygoma was impacted once onto the junction of the lower left spoke and rim with velocities ranging from 2.0 to 6.9 m/s. Generalized force histories were recorded with a six-axis load cell placed below the hub. The wheel was inclined 30 degrees to the horizontal. Steering wheel deformations were recorded with a system of potentiometers placed below the impact site on the wheel. Dynamic forces at the zygoma (impact site) were computed using transformation principles. A triaxial accelerometer was placed at the posterior parietal region of the specimen opposite to the impact site to record acceleration histories. High speed photography documented the kinematics.

In vitro biomechanical studies were conducted on fresh human cadaveric thoracolumbar spines to establish the limits of tolerance, explain the mechanism of failure, and investigate the effects of improvement in strength and stability of the injured column using Harrington distraction rods, Luque rods and modified Weiss springs. Quasistatic axial tensile loading on ligaments, compressive loads on vertebra) bodies and intervertebral discs, and flexure and compression-flexion force vectors on ligamentous columns, intact torsos and injured spines were applied to delineate the biomechanical and functional patho-anatomic characteristics. Vertical drop tests were conducted with the Hybrid II manikin to predict the forces and accelerations on the vertebral column.